Comprehensive Analysis of Tool Setters: Principles, Usage, Common Faults, and Professional Repair Guide

I. Principles of Tool Setters

Tool setters, precision instruments based on optical measurement technology, are widely used in CNC machine tools to accurately measure and calibrate the geometric shapes and dimensions of cutting tools. They ensure machining accuracy and stability. The tool setter consists of a light source, optical system, and detector. The light source emits light that passes through the optical system and illuminates the tool. The reflected light from the tool’s surface passes through the optical system again and is received by the detector. The detector converts the received light signals into electrical signals, which are processed by a computer to determine the tool’s geometric shape and dimensions. The measurement accuracy of the tool setter depends on the precision of the optical system and the sensitivity of the detector, requiring high-precision optical components and highly sensitive detectors for manufacturing.

II. Usage Methods

The usage of tool setters varies slightly depending on their type (contact or non-contact), but the basic steps are similar:

1. Installation: Secure the tool setter in an appropriate location on the CNC machine, such as the tool turret or worktable, ensuring a firm installation.
2. Power and Communication Connection: If the tool setter requires power or communication with the CNC system, ensure correct connections.
3. Cleaning: Clean the tool setter and tool to remove dust, oil, or metal chips.
4. System Setup: Make necessary settings in the CNC system, including selecting the tool setter type and inputting tool setter position parameters.
5. Calibration: Use a standard tool with known dimensions for initial calibration to ensure measurement accuracy.
6. Initiate Tool Setting Program: Select or start the tool setting program in the CNC system, and execute corresponding operations based on the tool setter type (contact or non-contact).
   • Contact Type: Slowly move the tool until it contacts the probe and record the trigger point.
   • Non-contact Type (e.g., Laser Tool Setter): Position the tool under the beam, and the system automatically records the data.
7. Data Processing: The tool setter sends the tool’s length and diameter data to the CNC system, which updates the tool compensation values accordingly.
8. Save Settings and Test Cut: Ensure that the tool setting data is correctly saved in the CNC system, and perform a brief test cut or dry run to verify the accuracy of the tool settings.

III. Common Faults and Repair Methods

Common faults and their repair methods for tool setters include:

1. Inaccurate or Unstable Measurements:
   • Cause: Worn components, contaminated optical system.
   • Repair: Replace worn components (such as measuring surfaces or mechanical contact points), clean the optical system and lenses.
2. No Signal Output or Abnormal Signal:
   • Cause: Circuit board failure, damaged sensor, or wiring issues.
   • Repair: Inspect and replace the circuit board, sensor, or wiring.
3. Large Deviation in Measurement Results:
   • Cause: Inaccurate calibration or incorrect parameter settings.
   • Repair: Recalibrate the tool setter, adjust CNC system parameters.
4. Intermittent Faults or Decreased Accuracy:
   • Cause: Aging seals, accumulation of dust.
   • Repair: Thoroughly clean the tool setter, replace seals.

During repairs, use specialized tools for disassembly and assembly to avoid damaging precision components. Conduct repairs in a clean, dust-free environment. Stock common spare parts to reduce downtime and keep detailed records of repair processes and replaced components. After repairs, conduct comprehensive testing to ensure proper functionality. For complex faults, especially those involving precision electronic components, it is recommended to seek assistance from the manufacturer or professional repair services. Within the warranty period, repairs should be handled by authorized service providers.

IV. Brands and Models of Tool Setters Repaired by Longi Electromechanical

1. Renishaw
   • OTS Series: OTS
   • NC4 Series: NC4
   • RMP60 Series: RMP60
   • HPMA Series: HPMA
   • TS27R: Tool Setter
2. Blum-Novotest
   • Z-Nano Series: Z-Nano
   • Z-Pico Series: Z-Pico
   • LC50 Series: LC50-DIGILOG
   • TC Series: TC52, TC76
3. Marposs
   • Mida Series: Mida Laser Tool Setter (LTS), Mida NTK, Mida VTS
   • TS Series: TS10, TS20
4. Heidenhain
   • TT Series: TT 160, TT 460
   • TL Series: TL Micro
5. Zoller
   • smile Series: smile / pilot 2.0
   • venturion Series: venturion 450, venturion 600
   • pom Series: pomBasic, pomSeries
6. Hexagon (m&h)
   • 4100 Series: m&h 41.00
   • 61.00 Series: m&h 61.00-PP
   • 78.00 Series: m&h 78.00-LTS
7. HAIMER
   • Microset Series: VIO linear tool presetter, UNO smart, UNO premium
8. BIG KAISER
   • BK Mikro Series: BK Mikro9, BK Mikro8
   • EWA Series: EWA Automatic Boring Tool
9. Nikken
   • Elbo Controlli Series: E46L, E68, E82
10. Speroni
    • MAGIS Series: MAGIS
    • STP Series: STP ESSENTIA, STP FUTURA
11. EZset
    • EZ Series: EZset IC2, EZset IC3D
    • IC Series: IC1, IC2
12. Omega
    • Digi-Pro Series: Digi-Pro
    • TT-1 Series: TT-1
13. Elbo Controlli
    • E46L: Portable Tool Setter
    • E68: High-Precision Tool Setter
    • E82: Multi-Function Tool Setter

Longi Electromechanical Company specializes in the repair and maintenance of tool setters and controllers, with nearly 30 years of experience. We offer prompt repairs for various instruments and also engage in the recycling and sales of tool setters and controllers. Feel free to contact us for more information.